Linde Forklift Truck 392 Series H20, H25 Service Training manual

Linde Forklift Truck 392 Series H20, H25 Service Training manual

Original Illustrated Factory Service Training Manual for Linde Forklift Trucks 392 Series with Diesel and LPG Engines

Covered Models:
H20D
H25D
H20T
H25T

Format: ZIP
Included:
Service Training manual PDF,459 pages
Diesel Truck Circuit Diagrams PDF, 247 pages
LPG Truck Circuit Diagrams PDF, 228 pages

Language: English

Table of contents:

0 Product information
Preface
The vehicle
Diagnostics
LHC basic structure
1 Engine
LPG engine
Description of the drive
Technical data for VWBEF ….
Engine block
Ribbed V-belt – removal and fitting
Toothed belt- removal and fitting, tensioning
Cylinder head -removal and fitting
Compression -check
Checking hydraulic bucket tappets
Cooling
Coolant thermostat- removal and installation
Water pump- removal and installation
Coolant pump -Checking for wear
Coolant -draining and filling
Engine electrics
Three-phase alternator
Electronic ignition system up to 08/2005, overview
Electronic ignition control unit
Electronic ignition system from 09/2005, overview
Shut-down due to lack of gas
LPG system
Safety guidelines for LPG (extract)
Basic rules when working with LPG
Sealing plastic pipe unions
Functions
LPG system – functions
Shut-off valve- LPG
Evaporator -functions
Mixer -functions
Basic setting of the butterfly valve until 12/2007
Revolution control (from 12/2007)
LPG system with lambda control
Exhaust gases -composition
Lambda control system
Checking and adjusting the mixer
Installation positions -Overview until 12/2007
Leakage test on LPG system
LPG tank
Level display with single replacement cylinders(special equipment)
Removing and installing the level display and 80 filling stop valve
The following safety measures must be observed
Carrying out assembly operations
Bleeding the LPG tank
The following safety measures must be observed
Procedure for bleeding
Diesel engine
Description of the drive
Technical data BEQ
Particularities of the 1.9-litre engine
Electronic engine control
Sensors
Coolant temperature sending unit 0B1
Engine speed sensor 0B2
Actual speed sensor 1B1
Fuel temperature sending unit 0B3
Suction pipe temperature sensor 0B4
Needle stroke sensor 0B5
Height sensor
0B3 control gate valve travel sensor
Glow plug system
Pre-heater system
Glow plugs- engine 0R1
Fuel supply
Fuel quantity regulation
Fuel quantity actuator 0B3
Fuel shut-off valve 0Y1
Injection timing device- replacement of O-ring on cover
Start of injection valve 0Y2
Start of injection -governing
Start of injection -dynamic checking and setting
Injection nozzle -Two-spring nozzle holder
Injection nozzles – removal and installation
One-way restrictor
Injection system -overview
Injection system -supply voltage check
Injection pump – removal and refitting, Exchanging the toothed belt
Injection pump – removal and installation
Injection pump – pump and toothed belt adjustment
Engine block
Ribbed V-belt- removal and fitting
Crankshaft oil seal on pulley end -removal and installation
Crankshaft sealing flange -removal and installation
Checking the cylinder head
Cylinder head -removal and fitting
Cylinder head -compression check
Valve gear
Oil pressure and oil pressure switch
– check
Oil sump – removal and installation
Checking hydraulic bucket tappets
Camshaft- removal and installation
Cooling
Coolant thermostat- removal and installation
Water pump – removal and installation
Coolant pump -Checking for wear
Coolant -draining and filling
Engine electrics
Three-phase alternator
Replacing the engine control unit/ immobilizer
Self-diagnostics
Self-test – introduction
Self-diagnostics -troubleshooting
Standardised measured value blocks
2 Axles
Description
Technical data for traction drive
System overview
Traction drive
Travel drive – introduction
Hydraulic adjustment with electronic activation- old version
Hydraulic adjustment with electronic activation- Version with round solenoids
Auxiliary brake valve until 06/2003
Auxiliary brake valve from 07/2003
Auxiliary brake valve from 1 0/2006
Start of variation of the variable displacement pump
Start of rotation of drive wheels
Removing and installing the HPV variable displacement pump coupling flange
Bypass valve
Output unit
Hydraulic fan drive
Hydraulic diagnostics
Overview and explanations about diagnostics
HPV 55-02 pressures -tests
Checking the hydrostatic traction drive
Wheel motor HMF 360 R-disassembly
Wheel motor HMF 360 R-checking bearing, seals
Wheel motor HMF 360 R – sealing after inspection
Wheel motor HMF 360 R-exchanging bearing
3 Chassis, bodywork and fittings
Chassis
Axle suspension
Instructions for working with gas springs
4 Undercarriage
Steering system
Steering system – schematic function
Steering axle
Steering axle general (302 and 1 602)
Steering axle removal and installation
Adjusting the steering stop
Repairs to the steering axle
Replacing the steering cylinder seals
Steering axle 302 up to 08/2009
Steering axle design
Steering axle number
Stub axle
Replacement of wheel bearings
Steering axle 1 602 from 09/2009
Steering axle 1602
Devices/tools for manual assembly
Process for manual removal
Removing the steering pivot pin (pressing out using a fixed press)
Removing the axle stub from the axle beam
Assembly process
Assembling the upper axle stub bearing and wiper
Assembly axle stub
Assembly lower axle stub bearing wiper
Assembling (pre-assembling) the steering pivot pin (pressing in using a fixed press)
Assembling the steering pivot pin (pressing in using a fixed press)
Assembling the lower axle stub bearing/flange cover
Assembly steering angle sensor/cover
Removal/assembly of the wheel hub/wheel bearing
Brake system
Brake release valve
Brake cables -adjustment
Checking the brake system
5 Operating devices
Accelerator
Function
Replacement
Stop screws
Joysticks
Joystick variants
Functional description
Replacement
6 Electrics/Electronics
General
Safety information for the electrical system
EMC- Electromagnetic compatibility
Electrostatic charging
Identifying components in electrical circuit diagrams
CAN bus
CAN bus connection assembly X15
Central electrical system
Linde Hydraulic Control (LHC)
LHC cont roller with ECO mode
Arrangement ofthe interface connectors console -truck
Layout of relays and fuses for standard and optional equipment
Display unit up to 06/2010
Display unit until 06/2010
Display unit from 07/2010
Display unit
Checks
LHC testing (truck control unit and lift control)
LHCcontrollerwithECOmode
Testing the VW controller and immobiliser (WFS)
Checking wiring harness
Testing sensors
Testing the indicator unit
7 Hydraulic equipment
Operating hydraulics
Functional characteristics of control valve until 10/2005
Overview
Functional description of control valve up to 1 0/2005
Pressure relief valve
Operating hydraulics circuit diagram until 1 0/2005
Hose routing of pump- control valve
Hose routing of pilot oil pressure supply
Faultfinding the working hydraulic system
Functional characteristics of Linde control valve from 1 1/2005
Overview
Function characteristics
Pressure relief valve
Working hydraulics circuit diagram (Linde control valve)
Depressurisation Auxiliary hydraulics 1 and 2
Hose layout pump -control valve
Hose layout control pressure supply
Gleaning work on the Linde control valve -cast valve
Cleaning instructions
8 Load lift system
Lift mast
Lift mast – identification
Mast – removal and installation (all series)
Installation of mast type 185
A dusting the lift chain (all series)
Setting the roller play
Roller clearance -fork carriage in inner mast
Roller clearance -middle and inner mast channel, type 185
Roller play -outer mast profile, series 185
Removal of slide pads – standard mast
Removal of slide pads – duplex mast
Removal of slide pads -triplex mast
Lift cylinder (outer)
– removal and installation
Lift cylinder (centre) – removal and installation
Lift cylinder -sealing
Tilt cylinder
Setting the tilt angle sensor
Hose reservoir – removal, exchanging hose, sealing, fitting
Line break safety device in the lift mast (butterfly valve)
9 Special equipment, accessories
Lighting
Working spotlight position
Annex
10 Circuit diagrams
Hydraulic circuit diagrams
Traction, working and steering hydraulics
Accumulator
Wiring diagrams
Basic equipment for diesel sheet 1
Basic equipment for diesel sheet 2
Basic equipment for diesel sheet 3
Basic equipment for LPG sheet 1
Basic equipment for LPG sheet 2
Basic equipment for LPG sheet 3
Special equipment sheet 01 -Working spotlights, interior light
Special equipment sheet 02 – Windscreen wiper, seat heater, radio
Special equipment sheet 03 – Heating system, air conditioning, flashing beacon / rotating

beacon, reversing signal
Special equipment sheet 04 – Hazard warning system for reverse travel
Special equipment sheet 05 – Lift mast positioning, hydraulic oil microfilter indicator, truck

deactivation, truck data management
Special equipment sheet 06 – Particle filter, diesel filter water trap warning .
Special equipment sheet 07 – Amount of gas display, 12V socket, coolant and engine oil level

monitoring
Special equipment sheet 08 – Battery mainswitch with display unit powersupply, changing

particle filter, rear window heating, camera system
Special equipment sheet 09 – Third auxiliary hydraulics with third joystick, centre rear

brake/tail light
Special equipment sheet 1 0
– Single lever locked, third auxiliary hydraulics via joystick
Special equipment sheet 11- Single lever locked, third auxiliary hydraulics via switch
Special equipment sheet 1 2
– Lighting, direction indicator and hazard warning system, brake light
Special equipment sheet 13 – Higher lighting, higher direction indicator and hazard warning

system, higher brake light and reversing light
Special equipment sheet 14 – Higher front / standard rear lighting

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